A Guide To Freeze Drying for the Laboratory
An Industry Service Publication 2 Foreword Introduction
This booklet has been developed to serve as a basic Freeze drying has been used in a number of guide to the freeze drying process. The information applications for many years, most commonly in the food presented is generic in nature and is the result of and pharmaceutical industries. There are, however, many research and experience by Labconco personnel and other uses for the process including heat-sensitive users of freeze drying equipment. It is our intention to sample preparation, plant material research, the provide a non-biased review of preparation techniques stabilization of living materials such as microbial and freeze drying methods. The purpose of this booklet is cultures, long term storage of HPLC samples, to help you make an informed choice of equipment for preservation of whole animal specimens for museum your laboratory applications. display, restoration of books and other items damaged by water, and the concentration and recovery of reaction products. Specialized equipment is required to create the Our Method conditions conducive to the freeze drying process. This equipment is currently available and can accommodate freeze drying of materials from laboratory scale projects We begin our discussion of freeze drying for the to industrial production. laboratory by examining the three steps in the process: Freeze drying involves the removal of water or other prefreezing, primary drying and secondary drying. Next, solvent from a frozen product by a process called we examine a typical freeze drying cycle and the methods sublimation. Sublimation occurs when a frozen liquid available to facilitate the freeze drying process using goes directly to the gaseous state without passing equipment designed for use by laboratories. Finally, through the liquid phase. In contrast, drying at ambient suggestions to optimize successful results are discussed, temperatures from the liquid phase usually results in including determination of end point, contamination, changes in the product, and may be suitable only for backfilling of dried samples and product stability. some materials. However, in freeze drying, the material A glossary of terms used throughout this booklet to does not go through the liquid phase, and it allows the explain the freeze drying process follows the text, along preparation of a stable product that is easy to use and with a bibliography. aesthetic in appearance. The advantages of freeze drying are obvious. Properly freeze dried products do not need refrigeration, and can be stored at ambient temperatures. Because the cost of the specialized equipment required for freeze drying can be substantial, the process may appear to be an expensive undertaking. However, savings realized by stabilizing an otherwise unstable product at ambient temperatures, thus eliminating the need for refrigeration, more than compensate for the investment in freeze drying equipment.
3 Principles of Freeze Drying vapor pressure of the product compared to the vapor pressure of the ice collector. Molecules migrate from the higher pressure sample to a lower pressure area. Since The freeze drying process consists of three stages: vapor pressure is related to temperature, it is necessary prefreezing, primary drying, and secondary drying. that the product temperature is warmer than the cold Prefreezing: Since freeze drying is a change in state trap (ice collector) temperature. It is extremely from the solid phase to the gaseous phase, material to be important that the temperature at which a product is freeze dried must first be adequately prefrozen. The freeze dried is balanced between the temperature that method of prefreezing and the final temperature of the maintains the frozen integrity of the product and the frozen product can affect the ability to successfully freeze temperature that maximizes the vapor pressure of the dry the material. product. This balance is key to optimum drying. The Rapid cooling results in small ice crystals, useful in typical phase diagram shown in Figure 1 illustrates this preserving structures to be examined microscopically, point. Most products are frozen well below their eutectic but resulting in a product that is more difficult to or glass transition point (Point A), and then the freeze dry. Slower cooling results in larger ice crystals temperature is raised to just below this critical and less restrictive channels in the matrix during the temperature (Point B) and they are subjected to a drying process. reduced pressure. At this point the freeze drying process Products freeze in two ways, depending on the is started. makeup of the product. The majority of products that are subjected to freeze drying consist primarily of water, the Figure 1 solvent, and the materials dissolved or suspended in the water, the solute. Most samples that are to be freeze dried F are which are a mixture of substances that U eutectics S I O CRITICAL freeze at lower temperatures than the surrounding water. N POINT L Liquid E I When the aqueous suspension is cooled, changes occur N IN E Phase L in the solute concentrations of the product matrix. And N IO T A as cooling proceeds, the water is separated from the A IZ R O solutes as it changes to ice, creating more concentrated P A areas of solute. These pockets of concentrated materials Solid V Vapor PRESSURE Phase have a lower freezing temperature than the water. Phase B TRIPLE E POINT N Although a product may appear to be frozen because of LI N TIO all the ice present, in actuality it is not completely frozen MA UBLI C until all of the solute in the suspension is frozen. The S D mixture of various concentration of solutes with the solvent constitutes the eutectic of the suspension. Only TEMPERATURE when all of the eutectic mixture is frozen is the suspension properly frozen. This is called the eutectic temperature. A typical phase diagram. It is very important in freeze drying to prefreeze the Some products such as aqueous sucrose solutions can product to below the eutectic temperature before undergo structural changes during the drying process beginning the freeze drying process. Small pockets of resulting in a phenomenon known as collapse. Although unfrozen material remaining in the product expand the product is frozen below its eutectic temperature, and compromise the structural stability of the freeze warming during the freeze drying process can affect the dried product. structure of the frozen matrix at the boundary of the The second type of frozen product is a suspension that drying front. This results in a collapse of the structural undergoes glass formation during the freezing process. matrix. To prevent collapse of products containing Instead of forming eutectics, the entire suspension becomes increasingly viscous as the temperature is lowered. Finally the product freezes at the glass transition point forming a vitreous solid. This type of product is extremely difficult to freeze dry. Primary drying: Several factors can affect the ability to freeze dry a frozen suspension. While these factors can be discussed independently, it must be remembered that they interact in a dynamic system, and it is this delicate balance between these factors that results in a properly freeze dried product. After prefreezing the product, conditions must be established in which ice can be removed from the frozen product via sublimation, resulting in a dry, structurally intact product. This requires very careful control of the two parameters, temperature and pressure, involved in the freeze drying system. The rate of sublimation of ice A vacuum pump is essential to evacuate the from a frozen product depends upon the difference in environment around the product to be freeze dried.
4 sucrose, the product temperature must remain below a A third component essential in a freeze drying system critical collapse temperature during primary drying. The is energy. Energy is supplied in the form of heat. Almost collapse temperature for sucrose is -32° C. ten times as much energy is required to sublime a gram No matter what type of freeze drying system is used, of water from the frozen to the gaseous state as is conditions must be created to encourage the free flow of required to freeze a gram of water. Therefore, with all water molecules from the product. Therefore, a vacuum other conditions being adequate, heat must be applied to pump is an essential component of a freeze drying the product to encourage the removal of water in the system, and is used to lower the pressure of the form of vapor from the frozen product. The heat must be environment around the product (to Point C). The other very carefully controlled, as applying more heat than the essential component is a collecting system, which is a evaporative cooling in the system can remove warms the cold trap used to collect the moisture that leaves the product above its eutectic or collapse temperature. frozen product. The collector condenses out all Heat can be applied by several means. One method is condensable gases, i.e; the water molecules, and the to apply heat directly through a thermal conductor shelf vacuum pump removes all non-condensable gases. such as is used in tray drying. Another method is to use ambient heat as in manifold drying. Secondary drying: After primary freeze drying is complete, and all ice has sublimed, bound moisture is still present in the product. The product appears dry, but the residual moisture content may be as high as 7-8%. Continued drying is necessary at the warmer temperature to reduce the residual moisture content to optimum values. This process is called isothermal desorption as the bound water is desorbed from the product. Secondary drying is normally continued at a product